Thermoplastic Composite Part Manufacturing System and Method

ABSTRACT

A method and apparatus for a continuous compression molding machine. The continuous compression molding machine comprises a tooling die, extending through a heating zone and a cooling zone, a tooling sleeve, and a biasing system. The tooling sleeve corresponds to the tooling die and is for use in forming a thermoplastic composite part from a thermoplastic composite charge when the tooling sleeve with the thermoplastic composite charge is moved with respect to the tooling die through the heating zone and the cooling zone. The biasing system is configured to hold the thermoplastic charge at a first angle within the heating zone and hold the thermoplastic composite charge at a second angle within the cooling zone, as the tooling sleeve moves through the heating zone and the cooling zone with the thermoplastic composite charge. The first angle is different from the second angle.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a divisional of U.S. patent application Ser. No.15/496,302, filed Apr. 25, 2017, the disclosure of which is incorporatedby reference herein in its entirety.

GOVERNMENT LICENSE RIGHTS

This disclosure was made with United States Government support underContract No. FA8650-14-C-5612. The United States Government has certainrights in this disclosure.

BACKGROUND INFORMATION 1. Field

The present disclosure relates generally to manufacturing compositeparts and, in particular, to a system and method for manufacturingthermoplastic composite parts.

2. Background

In the manufacturing of composite parts, continuous compression moldingmay be used to form thermoplastic composite parts. With this type ofmanufacturing, materials such as continuous fiber reinforcementspre-impregnated with high-end thermoplastics may be used. These types ofmaterials may include, for example, polyetheretherketone (PEEK),polyetherketoneketone (PEKK), polyetherimide (PEI), polyphenylenesulfide (PPS)resins, and carbon or fiberglass unidirectional or fabricfiber reinforcements. The composite parts may take various forms suchas, for example, an I beam. The flanges of the I beam may springinwardly as the part moves from a heating zone to a cooling zone duringa continuous compression molding consolidation cycle and is subsequentlyremoved from the continuous compression molding machine.

Currently, this type of spring back is taken into account by holdingportions of the thermoplastic composite part in a more open position.For example, the flanges of the I beam may be held open to a constantangle of 92 degrees such that when the part is removed from the sleeveof the continuous compression machine, the flanges spring back to thedesired 90 degrees.

However, this technique results in reduced structural integrity andgeometric consistency. This reduction in structural integrity may becaused by residual stresses present in locations such as the cornerradii of the I beam. The reduction in geometric consistency can createfit problems when installed into an assembly with other components.

Therefore, it would be desirable to have a method and apparatus thattake into account at least some of the issues discussed above, as wellas other possible issues. For example, it would be desirable to have amethod and apparatus that overcome a technical problem withmanufacturing thermoplastic composite parts with a desired level ofintegrity.

SUMMARY

An embodiment of the present disclosure provides for a continuouscompression molding machine. The continuous compression molding machinecomprises a tooling die, extending through a heating zone and a coolingzone, a tooling sleeve, and a biasing system. The tooling sleevecorresponds to the tooling die and is for use in forming a thermoplasticcomposite part from a thermoplastic composite charge when the toolingsleeve, with the thermoplastic composite charge, is moved with respectto the tooling die through the heating zone and the cooling zone. Thebiasing system is configured to hold the thermoplastic charge at a firstangle within the heating zone and hold the thermoplastic compositecharge at a second angle within the cooling zone, as the tooling sleevemoves through the heating zone and the cooling zone with thethermoplastic composite charge. The first angle is different from thesecond angle.

Another embodiment of the present disclosure provides for a method forforming a thermoplastic composite part in a continuous compressionmolding machine. The method comprises moving a thermoplastic compositecharge for forming the thermoplastic composite part with a toolingsleeve. The tooling sleeve corresponds to a tooling die with respect tothe tooling die in a heating zone, wherein the tooling sleeve and thetooling die are located in a continuous compression tooling machine. Themethod holds the thermoplastic composite charge at a first angle withinthe heating zone using a biasing system. The method moves thethermoplastic composite charge through a cooling zone. The method holdsthe thermoplastic composite charge at a second angle within the coolingzone using the biasing system in the continuous compression moldingmachine, wherein the first angle is different from the second angle.

The features and functions can be achieved independently in variousembodiments of the present disclosure or may be combined in yet otherembodiments in which further details can be seen with reference to thefollowing description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and features thereof, will best be understood by reference tothe following detailed description of an illustrative embodiment of thepresent disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is an illustration of a block diagram of a thermoplasticcomposite part manufacturing environment in accordance with anillustrative embodiment;

FIG. 2 is an illustration of a block diagram of a continuous compressionmolding machine in accordance with an illustrative embodiment;

FIG. 3 is an illustration of a block diagram of angles for a tooling dieand a tooling sleeve in accordance with an illustrative embodiment;

FIG. 4 is an illustration of a block diagram of a biasing system inaccordance with an illustrative embodiment;

FIG. 5 is an illustration of a continuous compression molding machine inaccordance with an illustrative embodiment;

FIG. 6 is an illustration of cross-sectional view of a continuouscompression molding machine in accordance with an illustrativeembodiment;

FIG. 7 is an illustration of an end of a continuous compression moldingmachine in accordance with an illustrative embodiment;

FIG. 8 is an illustration of an end of a continuous compression moldingmachine with a thermoplastic composite charge in accordance with anillustrative embodiment;

FIG. 9 is an illustration of a lower guide bar in accordance with anillustrative embodiment;

FIG. 10 is an illustration of angles on tooling dies in accordance withan illustrative embodiment;

FIG. 11 is an illustration of a flowchart of a process for forming athermoplastic composite part in accordance with an illustrativeembodiment;

FIG. 12 is an illustration of a flowchart of a process for determining atransition section in accordance with an illustrative embodiment;

FIG. 13 is an illustration of a block diagram of an aircraftmanufacturing and service method in accordance with an illustrativeembodiment;

FIG. 14 is an illustration of a block diagram of an aircraft in which anillustrative embodiment may be implemented; and

FIG. 15 is an illustration of a block diagram of a product managementsystem in accordance with an illustrative embodiment.

DETAILED DESCRIPTION

The illustrative embodiments recognize and take into account one or moredifferent considerations. For example, the illustrative embodimentsrecognize and take into account that increasing the structural integrityand geometric consistency of a thermoplastic composite part may beachieved by reducing residual stresses or other undesired conditionsthat occur when a portion of the thermoplastic composite part springsback after the thermoplastic composite part is removed from thecontinuous compression molding machine. The illustrative embodimentsrecognize and take into account that changing the angle of the partsduring the manufacturing of the thermoplastic composite parts to takeinto account the amount of spring back that may occur for a portion ofthe thermoplastic composite part may increase the structural integrity,as well as other parameters, of the thermoplastic composite part.

The illustrative embodiments provide a method and apparatus formanufacturing thermoplastic composite parts. In one illustrativeexample, a continuous compression molding machine comprises a toolingdie, a tooling sleeve, and a biasing system. The tooling die extendsthrough a heating zone and a cooling zone. The tooling sleevecorresponds to the tooling die for forming a thermoplastic compositepart from a thermoplastic composite charge when the tooling sleeve, withthe thermoplastic composite charge, is moved with respect to the toolingdie through the heating zone and the cooling zone. The biasing system isconfigured to hold the thermoplastic composite charge at a first anglewithin the heating zone and hold the thermoplastic composite charge at asecond angle within the cooling zone as the tooling sleeve moves throughthe heating zone and the cooling zone with the thermoplastic compositecharge. The first angle is different from the second angle.

With reference now to the figures, and in particular, with reference toFIG. 1, an illustration of a block diagram of a thermoplastic compositepart manufacturing environment is depicted in accordance with anillustrative embodiment. As depicted, thermoplastic composite partmanufacturing environment 100 includes continuous compression moldingfabrication line 102. In this example, continuous compression moldingfabrication line 102 operates to manufacture thermoplastic compositeparts 104.

Thermoplastic composite parts 104 is comprised of one or morethermoplastic materials that may be reheated to change the shape ofthermoplastic composite parts 104. Typically, the thermoplasticmaterials are used in resins for thermoplastic composite parts 104.

Thermoplastic composite parts 104 may take a number of different forms.For example, thermoplastic composite parts 104 may be stiffened membersthat have a cross-section selected from at least one of an I shape, aflat or curved plate shape, a Z shape, a U or C shape, a T shape, a hatshape, or some other suitable type of shape. One or more illustrativeexamples may be applied to any thermoplastic composite part that has afeature in which an angle or curve is present.

As used herein, the phrase “at least one of”, when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used, and only one of each item in the list may be needed. Inother words, “at least one of” means any combination of items and numberof items may be used from the list, but not all of the items in the listare required. The item may be a particular object, a thing, or acategory.

For example, without limitation, “at least one of item A, item B, oritem C” may include item A, item A and item B, or item B. This examplealso may include item A, item B, and item C or item B and item C. Ofcourse, any combinations of these items may be present. In someillustrative examples, “at least one of” may be, for example, withoutlimitation, two of item A, one of item B, and ten of item C; four ofitem B and seven of item C; or other suitable combinations.

The stiffened member may be straight, curved, have a uniform thickness,a non-uniform thickness, or some other suitable shape. Thermoplasticcomposite parts 104 may be used to form or used in a fuselage skin, awing skin, a control surface, a door panel, an access panel, a keelbeam, a floor beam, a deck beam, a stiffener, a clip, or some othersuitable type of application. The thermoplastic part also may beselected from a group comprising a beam, an I beam, a T beam, astringer, or some other type of part with a shape having angularfeatures.

In this illustrative example, continuous compression molding fabricationline 102 has a number of different components. As depicted, continuouscompression molding fabrication line 102 comprises preforming station106 and consolidation station 108.

Preforming station 106 is a portion of continuous compression moldingmachine 118 that receives composite materials 110. Composite materials110 are plies of composite material, filler material or other suitabletypes of material that may be used to form thermoplastic composite parts104. As depicted, the plies of composite material may be supplied fromat least one of continuous roles or stacks of precut blanks. In thisexample, composite materials 110 are thermoplastic composite materials.

Preforming station 106 may be used to align and guide the plies incomposite materials 110. Additionally, preforming station 106 may formfeatures such as flanges, curved sections, or other features forthermoplastic composite parts 104. The output of preforming station 106is thermoplastic composite charges 112. Thermoplastic composite charges112 generally have a shape for thermoplastic composite parts 104.

Thermoplastic composite charges 112 are sent into consolidation station108. Consolidation station 108 applies at least one of heat 114 orpressure 116 to thermoplastic composite charges 112, while thermoplasticcomposite charges 112 move through consolidation station 108. The outputfrom consolidation station 108 is thermoplastic composite parts 104.

In this illustrative example, one or more features in the illustrativeexamples may be implemented using continuous compression molding machine118 in consolidation station 108. Continuous compression molding machine118 may be configured in a manner that increases desired characteristicsof thermoplastic composite parts 104. For example, thermoplasticcomposite parts 104 may have at least one of increased structuralintegrity, strength, longevity, or other desired characteristicsrelative to parts not manufactured using continuous compression moldingmachine 118.

With reference now to FIG. 2, an illustration of a block diagram of acontinuous compression molding machine is depicted in accordance with anillustrative embodiment. This figure illustrates examples of componentsthat may be used in continuous compression molding machine 118 in FIG.1.

In the illustrative example, continuous compression molding machine 118is comprised of a number of different components. As depicted,continuous compression molding machine 118 includes tooling die system200, tooling sleeve 202, biasing system 204, and heating system 206.

In this illustrative example, heating system 206 comprises heating zone214 and cooling zone 216. Each of the zones may have sub-zones in whichthe temperatures are selected for each of the zones. For example,heating zone 214 may have a group of heating sub-zones 218 in which eachsub-zone has a different temperature for heating thermoplastic compositecharge 222 as part of the process for forming thermoplastic compositepart 224. As another example, cooling zone 216 may have a group ofcooling sub-zones 220.

As used herein, a “group of” when used with reference items means one ormore items. For example, a group of heating sub-zones 218 is one or moreheating sub-zones.

In this illustrative example, thermoplastic composite charge 222 is anexample of a charge in thermoplastic composite charges 112 in FIG. 1.Thermoplastic composite part 224 is an example of a part inthermoplastic composite parts 104 in FIG. 1.

In the illustrative example, tooling die system 200 includes tooling die226. Tooling die 226 extends through heating zone 214 and cooling zone216 in heating system 206.

As depicted, tooling sleeve 202 corresponds to tooling die 226 forforming thermoplastic composite part 224 from thermoplastic compositecharge 222 when tooling sleeve 202 with thermoplastic composite charge222 are moved with respect to tooling die 226 through heating zone 214and cooling zone 216. In this illustrative example, tooling sleeve 202corresponds to tooling die 226 by having a similar shape that allows fortooling sleeve 202 to slide or move along tooling die 226.

For example, tooling sleeve 202 may have a U-shape that allows fortooling sleeve 202 to cover the U-shape and slide or move along thelength of tooling die 226. In the illustrative example, tooling sleeve202 holds thermoplastic composite charge 222. Tooling sleeve 202 islocated between thermoplastic composite charge 222 and tooling die 226in this depicted example.

Biasing system 204 is configured to hold thermoplastic composite charge222 at first angle 228 within heating zone 214 and hold thermoplasticcomposite charge 222 at second angle 230 within cooling zone 216 astooling sleeve 202 moves through heating zone 214 and cooling zone 216with thermoplastic composite charge 222. In this depicted example, firstangle 228 is different from the second angle 230. In other words, thesetwo angles have different values.

In this illustrative example, tooling die 226 is upper tooling die 232and tooling sleeve 202 is first tooling sleeve 234. As depicted, toolingdie system 200 also includes lower tooling die 236, in which lowertooling die 236 extends through heating zone 214 and cooling zone 216.Second tooling sleeve 238 also is present and corresponds to lowertooling die 236 for forming thermoplastic composite part 224 fromthermoplastic composite charge 222 when thermoplastic composite charge222 is moved with respect to lower tooling die 236 through heating zone214 and cooling zone 216.

In this illustrative example, first tooling sleeve 234 and secondtooling sleeve 238 are part of tooling sleeve system 240. Biasing system204 is configured to cause first tooling sleeve 234 and second toolingsleeve 238 to hold portions 242 of the thermoplastic composite charge222 at a group of first angles 244 within heating zone 214 and holdportions 242 of thermoplastic composite charge 222 at a group of secondangles 246 within cooling zone 216 as first tooling sleeve 234 andsecond tooling sleeve 238 move through heating zone 214 and cooling zone216 with thermoplastic composite charge 222.

In the illustrative example, different angles may be present within thegroup of first angles 244, and different angles may be present withinthe group of second angles 246. For example, a first angle in the groupof first angles 244 for first tooling sleeve 234 may be different fromthe first angle in the group of first angles 244 for second toolingsleeve 238.

In this example, thermoplastic charge 222 has flange 250. Flange 250 isheld at first angle 228 in heating zone 214 and at second angle 230 incooling zone 216.

With reference to FIG. 3, an illustration of a block diagram of anglesfor a tooling die and a tooling sleeve is depicted in accordance with anillustrative embodiment. In this illustrative example, tooling die 300is a tooling die within tooling die system 200 of FIG. 2. Tooling die300 has first section 304 and second section 306. As depicted, firstsection 304 has first angle 308 and second section 306 has second angle310.

Tooling sleeve 312 is a tooling sleeve within tooling sleeve system 240of FIG. 2. In this example, tooling sleeve 312 corresponds to toolingdie 300. The correspondence in this example is one in which toolingsleeve 312 has a shape similar to tooling die 300, such that toolingsleeve 312 may move along tooling die 300 using tooling die 300 as aguide for movement.

In this illustrative example, when tooling sleeve 312 to moves throughfirst section 304 in tooling die 300, tooling sleeve 312 has first angle308. In this example, tooling sleeve 312 has first angle 308 withoutbeing biased. If tooling sleeve 312 normally has first angle 308,tooling sleeve 312 is biased or put under pressure by biasing system 204to have second angle 310 when tooling sleeve 312 is in second section306 of tooling die 300.

For example, biasing system 204 applies pressure against tooling sleeve312 to change from first angle 308 to second angle 310 with toolingsleeve 312 being located between biasing system 204 and tooling die 300.In other words, biasing system 204 applies pressure on tooling sleeve312 to bend towards tooling die 300 to obtain second angle 310. Firstangle 308 and second angle 310 are different from each other with firstangle 308 being greater than second angle 310 in this particularexample.

When tooling sleeve 312 moves into second section 306, biasing system204 biases or applies pressure against tooling sleeve 312. This changein pressure by biasing system 204 allows tooling sleeve 312 change tosecond angle 310. This change in angles for tooling sleeve 312 resultsin a corresponding change to thermoplastic charge 314 carried on toolingsleeve 312 and changes angles in a similar manner.

In this illustrative example, continuous compression molding machine 118of FIG. 1 also may include transition section 316 in at least one ofheating zone 214 or cooling zone 216, shown in FIG. 2, in which atransition from first angle 308 to second angle 310 occurs. Thetransition is in tooling die 300. This transition in tooling die 300also causes a transition in tooling sleeve 312 as biasing system 204applies pressure on tooling sleeve 312 towards tooling die 300.

The length of transition section 316, location of transition section316, and rate at which first angle 308 changes to second angle 310 intransition section 316, as well as other parameters, depends on a numberof different factors. For example, the factors may be selected from atleast one of material use, part geometry, part thickness, heating rate,cooling rate, and other suitable parameters. The selection of the lengthof transition section 316 and the rate at which first angle 308 changesto second angle 310 may be made to reduce stress when formingthermoplastic composite part 318 from thermoplastic charge 314.

In the illustrative example, the change from first angle 308 to secondangle 310 does not occur abruptly. Instead, the change from first angle308 to second angle 310 may occur over some distance extending throughat least one of heating zone 214 and cooling zone 216.

The distance selected is based on a number of different factors. In theillustrative example, the factors considered in establishing thedistance over which the angle changes from first angle 308 to secondangle 310 includes at least one of a material property for the part, amaterial property for the tool, a processing temperature, a processingrate, a cooling rate, a part geometry, or a tool geometry.

With reference now to FIG. 4, an illustration of a block diagram of abiasing system is depicted in accordance with an illustrativeembodiment. In this figure, an example of components that may be used toimplement biasing system 204 are shown. In this illustrative example,biasing system 204 includes guide bar 400 and seal bar 402.

Seal bar 402 primarily functions to reduce or prevent a thermoplasticcharge from flowing in an undesired manner. Seal bar 402 appliespressure to create a seal with respect to the thermoplastic charge.Further, in this illustrative example, seal bar 402 applies pressureagainst a tooling sleeve to maintain a desired angle of the toolingsleeve.

As depicted, springs 404 bias seal bar 402 towards a tooling sleeve.Springs 404 may take a number of forms. For example, springs 404 may beselected from at least one of a Belleville washer, a coil spring, a leafspring, a compression spring, a variable spring, a flat spring, aserpentine spring, a cantilever spring, or other suitable types ofsprings.

As depicted, guide bar 400 holds a tooling sleeve at the second angle inthe cooling zone, such that the composite charge has the second angle.The guide bar is comprised of elongate member 406 and guiding elements408. Guiding elements 408 apply pressure to the tooling sleeve, suchthat the tooling sleeve has the second angle. As depicted, a transitionmay be present from the first angle to the second angle.

In this illustrative example, guiding elements 408 may take a number ofdifferent forms. Guiding elements 408 may be selected from at least oneof a pin with rounded edges, a roller, a wheel, or some other suitabletype of guiding element.

In one illustrative example, one or more technical solutions are presentthat overcome a technical problem with manufacturing thermoplasticcomposite parts with a desired level of integrity. As a result, one ormore technical solutions may provide a technical effect in increasingthe level of integrity of thermoplastic composite parts, in addition toincreasing other characteristics of the thermoplastic composite parts.For example, thermoplastic composite parts manufactured using one ormore of the illustrative examples may have at least one of increasedstrength, reduced maintenance, increased longevity, or other desirablecharacteristics.

The illustration of thermoplastic composite part manufacturingenvironment 100 and the different components in FIGS. 1-4 are not meantto imply physical or architectural limitations to the manner in which anillustrative embodiment may be implemented. Other components, inaddition to or in place of the ones illustrated, may be used. Somecomponents may be unnecessary. Also, the blocks are presented toillustrate some functional components. One or more of these blocks maybe combined, divided, or combined and divided into different blocks whenimplemented in an illustrative embodiment.

With reference now to FIG. 5, an illustration of a continuouscompression molding machine is depicted in accordance with anillustrative embodiment. Continuous compression molding machine 500 isan example of one implementation for continuous compression moldingmachine 118 and the different components for continuous compressionmolding machine 118 shown in block form in FIGS. 1-4.

As depicted, continuous compression molding machine 500 comprisesplatform 502. In this illustrative example, tooling die 504 is uppertooling die 506 and is associated with top side 503 of platform 502.Platform 502 also has end 505, end 507, and bottom side 509.

Continuous compression molding machine 500 also includes lower toolingdie 508, side tooling die 510, and side tooling die 512. These toolingdies are also associated with platform 502.

When one component is “associated” with another component, theassociation is a physical association. For example, a first component,such as tooling die 504, may be considered to be physically associatedwith a second component, such as platform 502, by at least one of beingsecured to the second component, bonded to the second component, mountedto the second component, welded to the second component, fastened to thesecond component, or connected to the second component in some othersuitable manner. The first component also may be connected to the secondcomponent using a third component. The first component may also beconsidered to be physically associated with the second component bybeing formed as part of the second component, extension of the secondcomponent, or both. In some cases, the first component may be movablewith respect to the second component as part of being associated withthe second component. In this illustrative example, upper tooling die506 and lower tooling die 508 are fixed on platform 502. On the otherhand, side tooling die 510 and side tooling die 512 are moveablyconnected to platform 502.

In this illustrative example, tooling sleeve 514 is first tooling sleeve516 corresponding to upper tooling die 506. Second tooling sleeve 518corresponds to lower tooling die 508. As depicted both first toolingsleeve 516 and second tooling sleeve 518 move along upper tooling die506 and lower tooling die 508 in the direction of arrow 520.

As depicted, first tooling sleeve 516 has flexible flange 515. Secondtooling sleeve 518 has flexible flange 519. These flexible flanges maybe biased to different angles from the original angle for the toolingsleeves. These flexible flanges return to the original angles whenpressure is no longer applied to the flanges.

In this example, heating zone 522 and cooling zone 524 are present incontinuous compression molding machine 500. The temperatures in thesezones are generated by a heating system, not show in this figure.

Other components that are part of continuous compression molding machine500 are not shown in order to avoid obscuring the depiction anddescription of features for manufacturing a thermoplastic composite partwith increased integrity. For example, heaters, connections to heaters,and other components used in continuous compression molding machine 500are not shown in this view.

Also, shown in this view of continuous compression molding machine 500are lower seal bar 528, upper seal bar 529, upper guide bar 530, andlower guide bar 534. As depicted, lower seal bar 528 and upper seal bar529 are present in heating zone 522 and portion 531 of cooling zone 524.Upper guide bar 530 and lower guide bar 534 are present in cooling zone524. Lower guide bar 534 begins where lower seal bar 528 ends, and upperguide bar 530 begins where upper seal bar 529 ends. This change happensat a set point in cooling zone 524 when the part (not shown) issolidified, which is based on cooling rate, part geometry, materialusage, and other suitable factors.

The guide bars are used to do at least one of setting or changing theangles for first tooling sleeve 516 and second tooling sleeve 518. Thechange in these angles results in a change in the angles for features inthe thermoplastic composite part being formed from a thermoplasticcomposite charge. The seal bars hold the tooling sleeve at a desiredangle. The seal bars may be biased using a biasing system, such assprings, to hold at least one of first tooling sleeve 516 and secondtooling sleeve 518 at a desired angle.

For example, at least one of lower seal bar 528, upper seal bar 529,upper guide bar 530, or lower guide bar 534 sets the tooling sleeves todifferent angles for first tooling sleeve 516 and second tooling sleeve518 while these tooling sleeves move along upper tooling die 506 andlower tooling die 508, respectively, in the direction of arrow 520 incontinuous compression molding machine 500 shown in accordance with anillustrative embodiment.

In these illustrative examples, the biasing is performed using pressuresapplied to the tooling sleeves. Increasing or decreasing the pressuremay be used to change the angles for the tooling sleeves in a mannerthat changes the angles for the thermoplastic composite charges beingprocessed within continuous compression molding machine 500 to formthermoplastic composite parts.

These desired angles are obtained by biasing first tooling sleeve 516and second tooling sleeve 518 against upper tooling die 506 and lowertooling die 508, respectively. In other words, the tooling dies areconfigured as a template or guide to define the angles. Theconfiguration of these tooling dies changes over the length of thetooling dies to provide the different angles.

Turning now to FIG. 6, an illustration of a cross-sectional view of acontinuous compression molding machine is depicted in accordance with anillustrative embodiment. In this figure, a cross-sectional view ofcontinuous compression molding machine 500 taken along lines 6-6 in FIG.5 is depicted. Upper guide bar 530 and upper seal bar 529 are seen inthis cross-sectional view.

Biasing system 600 is seen in this figure. Biasing system 600 comprisescompression springs, such as compression spring 602, compression spring604, compression spring 606, compression spring 608, compression spring610, compression spring 612, and compression spring 614 in upper sealbar 529. Biasing system 600 also includes compression spring 616,compression spring 618, and compression spring 620 in upper guide bar530.

Turning now to FIG. 7, an illustration of an end of a continuouscompression molding machine is depicted in accordance with anillustrative embodiment. FIG. 7 shows a view of end 507 of continuouscompression molding machine 500.

In this view, an illustration of lower seal bar 528 is shown. Asdepicted, lower seal bar 528 comprises elongate member 700. Elongatemember 700 may be biased by biasing system 600 using the Bellevillewashers as described above.

Lower seal bar 528 may be biased away from second tooling sleeve 518with key 710 to allow for advancing first tooling sleeve 516 and secondtooling sleeve 518. In the illustrative example, key 710 is a piece ofbrass stock that fits into a slot in side tooling die 512. When sidetooling die 512 retracts, key 710 comes into contact with biasing system600. In the illustrative example, biasing system 600 may retract lowerseal bar 528 when side tooling die 512 opens. This movement reducesfriction between the sleeve and the die in case there is too muchfrictional force to pull the tooling sleeves with the composite chargethrough the dies.

Turning now to FIG. 8, an illustration of an end of a continuouscompression molding machine with a thermoplastic composite charge isdepicted in accordance with an illustrative embodiment. In thisillustrative example, end 505 of continuous compression molding machine500 is shown.

In this view, thermoplastic composite charge 800 is shown. In thisexample, first tooling sleeve 516 is located between thermoplasticcomposite charge 800 and upper tooling die 506. Similarly, secondtooling sleeve 518 is located between thermoplastic composite charge 800and lower tooling die 508. As depicted in this illustrative example,thermoplastic composite charge 800 is for a thermoplastic composite partin the form of an I-beam. In this illustrative example, thermoplasticcomposite charge 800 has side 808 and side 810. Flange 812 and flange814 are thin enough that spring back is present. On the other hand,flange 816 and flange 818 on side 808 have a thickness such that springback is not an issue in this particular example. As a result, the changein angles is only performed for side 810 of thermoplastic compositecharge 800.

In the illustrative example, the angle of flange 812 relative to mainstructure 804 of thermoplastic composite charge 800 is set by the angleof first tooling sleeve 516. The angle of flange 814 relative to mainstructure 804 is set by the angle of second tooling sleeve 518. Theangle of these tooling sleeves is based on the angle of upper toolingdie 506 and lower tooling die 508, respectively. For example, the anglesare for flexible flange 515 in first tooling sleeve 516 and flexibleflange 519 in second tooling sleeve 518.

In other words, first tooling sleeve 516 is biased against upper toolingdie 506 to set the angle for first tooling sleeve 516 based on the angleof upper tooling die 506. In a similar fashion, second tooling sleeve518 is biased against lower tooling die 508. As a result, the angle ofsecond tooling sleeve 518 is based on the angle of a part of lowertooling die 508.

In this illustrative example, flange 816 and flange 818 are thicker thanflange 812 and flange 814. As depicted, changing the angle of these twoflanges is not necessary, in this example, because spring back is not anissue with flange 816 and flange 818. Biasing of guide bars and sealbars on the other side of flange 816 and flange 818 are unnecessary inthis particular example. Thus, only one side of the tooling sleeves arebiased to change the angles in this illustrative example.

With reference to FIG. 9, an illustration of a lower guide bar isdepicted in accordance with an illustrative embodiment. In this figure,an illustration of lower guide bar 534 is provided. As depicted, lowerguide bar 534 comprises elongate member 900 and wheels 902. Wheels 902are examples of guiding members that may contact second tooling sleeve518 shown in FIG. 5.

Wheels 902 apply pressure to second tooling sleeve 518 to positionsecond tooling sleeve 518 against lower tooling die 508, shown in FIG.5, to obtain a second angle for second tooling sleeve 518. The secondangle for second tooling sleeve 518 also results in the thermoplasticcomposite charge being processed on second tooling sleeve 518 to formthe thermoplastic composite part having the second angle. In thismanner, lower guide bar 534 and other guide bars ensure that sleeves arepositioned against the different dies to obtain desired angles duringprocessing of thermoplastic composite charges to form thermoplasticcomposite parts.

Turning next to FIG. 10, an illustration of angles on tooling dies aredepicted in accordance with an illustrative embodiment. In this example,an illustration of upper tooling die 506 and lower tooling die 508 fromtop side 503 is depicted in accordance with an illustrative embodiment.

In this illustrative example, upper tooling die 506 and lower toolingdie 508 have an angle of 90 degrees on side 1000 and side 1006 as shownby line 1004 and line 1002 in heating zone 522 of FIG. 5. Top side 503is in cooling zone 524 of FIG. 5. Upper tooling die 506 and lowertooling die 508 have an angle of 92 degrees on side 1000 and side 1002at top side 503.

As shown in this example, the angle of upper tooling die 506 and lowertooling die 508 change over the length of these tooling dies. As aresult, when the tooling sleeves are biased against the tooling dies,angles also change as the tooling sleeves move along the tooling dies.

The illustration of continuous compression molding machine 500 in FIGS.5-10 are shown for purposes of illustrating one manner in whichcontinuous compression molding machine 118 shown in block form maybeimplemented and has a physical machine. Although Belleville washers areshown for biasing system 600, other types of biasing devices may beused. For example, any type of spring may be used, in addition to or inplace of the Belleville washers, in biasing system 600. For example, atleast one of a coil spring, a leaf spring, a compression spring, avariable spring, a flat spring, a serpentine spring, a cantileverspring, or other suitable types of springs may be used within biasingsystem 600.

As another example, another I beam may have thinner flanges on bothsides affected by spring back. With this type of thermoplastic compositepart, the tooling die have changes in the angles on both sides. Also,guide bars and seal bars are utilized on both sides to bias both flangesof the tooling sleeves against the tooling dies to take into account thespring back.

Thus, one or more illustrative examples allow for the manufacturing ofthermoplastic composite parts using flexible tooling sleeves withstrategic guiding rollers to allow for angle spring back compensationduring the manufacturing of thermoplastic composite parts. The flexibleflange in the tooling sleeve provides a “hinge point” in the toolingsleeve so that the flanges of the sleeve can rotate inwards as thesleeve runs through the continuous compression molding machine. Atooling sleeve with a flexible flange enables spring back compensationto reduce the residual stresses that develop during the manufacturingprocess. In this manner, the technical effect is present that improvesthe manufacturing precision and dimensional control of the angles inthermoplastic composite parts.

Turning next to FIG. 11, an illustration of a flowchart of a process forforming a thermoplastic composite part is depicted in accordance with anillustrative embodiment. The process illustrated in FIG. 11 may beimplemented in thermoplastic composite part manufacturing environment100 in FIG. 1. One or more of the different operations depicted may beprevented using continuous compression molding machine 118 and thecomponents for this machine as shown in block form in FIGS. 1-4.

The process begins by moving a thermoplastic composite charge with atooling sleeve corresponding to a tooling die with respect to thetooling die in a heating zone (operation 1100). The thermoplasticcomposite charge is used to form the thermoplastic composite part. Inthis illustrative example, the tooling sleeve and the tooling die arelocated in the continuous compression molding machine.

The process holds the thermoplastic composite charge at a first anglewithin the heating zone using a biasing system (operation 1102). Theprocess moves the thermoplastic composite charge through a cooling zone(operation 1104). The process holds the thermoplastic composite chargeat a second angle within the cooling zone using the biasing system inthe continuous compression molding machine (operation 1106). With theprocess terminating thereafter. The first angle is different from thesecond angle.

With this process, a portion of the tooling sleeve with thethermoplastic composite charge may be present in both the heating zoneand the cooling zone as the tooling sleeve moves along the tooling die.As a result, a portion of the tooling sleeve may have the first anglewhile still in the heating zone while another portion of the toolingsleeve may have the second angle while in the cooling zone.

With reference next to FIG. 12, an illustration of a flowchart of aprocess for determining a transition section is depicted in accordancewith an illustrative embodiment. This process may be used to determinetransition section 316 in FIG. 3.

The transition section is a length or distance along which the angle ischanged for a thermoplastic charge being processed to form thethermoplastic composite part. In other words, the transition section iswhere the angle is changed while the thermoplastic composite part isbeing fabricated on one or more tooling sleeves.

The process begins by identifying a group of factors affecting thestress on the thermoplastic composite part during fabrication of thethermoplastic composite part (operation 1200). These factors may includeat least one of material use, part geometry, part thickness, heatingrate, cooling rate, and other suitable parameters. In this illustrativeexample, the stress on the thermoplastic composite part may reflect atleast one of structural integrity, strength, frequency of maintenance,development of inconsistencies, or other parameters.

The process determines a rate of change from the first angle to thesecond angle and a length of the transition section (operation 1202).This rate of change may be constant or may vary within the transitionsection. For example, the angular change is calculated based on variousinputs including the composite part material properties, the compositepart material geometry, the tooling material properties, the toolingmaterial geometry, the processing parameters used for part fabrication,and other suitable parameters.

The process also determines a location for the transition section(operation 1204). The process terminates thereafter. For example, thetransition section may begin when the heating zone ends and the coolingzone begins. In some illustrative examples, the transition section maybegin at the end of the heating zone or some other location.

The flowcharts and block diagrams in the different depicted embodimentsillustrate the architecture, functionality, and operation of somepossible implementations of apparatuses and methods in an illustrativeembodiment. In this regard, each block in the flowcharts or blockdiagrams may represent at least one of a module, a segment, a function,or a portion of an operation or step. For example, one or more of theblocks may be implemented as program code, hardware, or a combination ofthe program code and hardware. When implemented in hardware, thehardware may, for example, take the form of integrated circuits that aremanufactured or configured to perform one or more operations in theflowcharts or block diagrams. When implemented as a combination ofprogram code and hardware, the implementation may take the form offirmware. Each block in the flowcharts or the block diagrams may beimplemented using special purpose hardware systems that perform thedifferent operations or combinations of special purpose hardware andprogram code run by the special purpose hardware.

In some alternative implementations of an illustrative embodiment, thefunction or functions noted in the blocks may occur out of the ordernoted in the figures. For example, in some cases, two blocks shown insuccession may be performed substantially concurrently, or the blocksmay sometimes be performed in the reverse order, depending upon thefunctionality involved. Also, other blocks may be added in addition tothe illustrated blocks in a flowchart or block diagram.

For example, the flowchart in FIG. 11 may include a transitioning zone.With a transitioning zone, the process may transition from holding thethermoplastic composite charge from the first angle to the second anglein transition section located in at least one of the heating zone or thecooling zone. The transition section is an area in which the angle atwhich the thermoplastic composite part changes.

The illustrative embodiments of the disclosure may be described in thecontext of aircraft manufacturing and service method 1300 as shown inFIG. 13 and aircraft 1400 as shown in FIG. 14. Turning first to FIG. 13,an illustration of a block diagram of an aircraft manufacturing andservice method is depicted in accordance with an illustrativeembodiment. During pre-production, aircraft manufacturing and servicemethod 1300 may include specification and design 1302 of aircraft 1400in FIG. 14 and material procurement 1304.

During production, component and subassembly manufacturing 1306 andsystem integration 1308 of aircraft 1400 in FIG. 14 takes place.Thereafter, aircraft 1400 in FIG. 14 may go through certification anddelivery 1310 in order to be placed in service 1312. While in service1312 by a customer, aircraft 1400 in FIG. 14 is scheduled for routinemaintenance and service 1314, which may include modification,reconfiguration, refurbishment, or other maintenance and service.

Each of the processes of aircraft manufacturing and service method 1300may be performed or carried out by a system integrator, a third party,an operator, or some combination thereof. In these examples, theoperator may be a customer. For the purposes of this description, asystem integrator may include, without limitation, any number ofaircraft manufacturers and major-system subcontractors; a third partymay include, without limitation, any number of vendors, subcontractors,and suppliers; and an operator may be an airline, a leasing company, amilitary entity, a service organization, and so on.

With reference now to FIG. 14, an illustration of a block diagram of anaircraft is depicted in which an illustrative embodiment may beimplemented. In this example, aircraft 1400 is produced by aircraftmanufacturing and service method 1300 in FIG. 13 and may includeairframe 1402 with plurality of systems 1404 and interior 1406. Examplesof systems 1404 include one or more of propulsion system 1408,electrical system 1410, hydraulic system 1412, and environmental system1414. Any number of other systems may be included. Although an aerospaceexample is shown, different illustrative embodiments may be applied toother industries, such as the automotive industry.

Apparatuses and methods embodied herein may be employed during at leastone of the stages of aircraft manufacturing and service method 1300 inFIG. 13. In one illustrative example, components or subassembliesproduced in component and subassembly manufacturing 1306 in FIG. 13 maybe fabricated or manufactured in a manner similar to components orsubassemblies produced while aircraft 1400 is in service 1312 in FIG.13.

As yet another example, one or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized during productionstages, such as component and subassembly manufacturing 1306 and systemintegration 1308 in FIG. 13. One or more apparatus embodiments, methodembodiments, or a combination thereof may be utilized while aircraft1400 is in service 1312, during maintenance and service 1314 in FIG. 13,or both.

For example, one or more illustrative embodiments may be used tomanufacture thermoplastic composite parts during one or more of thesedifferent stages of aircraft manufacturing and service method 1300. Forexample, thermoplastic composite parts may be manufactured duringcomponent and subassembly manufacturing 1306. These components may beused in producing aircraft 1400 for providing routine maintenance andservice 1314.

The use of a number of the different illustrative embodiments maysubstantially expedite the assembly of aircraft 1400, reduce the cost ofaircraft 1400, or both expedite the assembly of aircraft 1400 and reducethe cost of aircraft 1400. Thermoplastic composite parts manufactured inthermoplastic composite part manufacturing environment 100 may havelonger lifespans, increased structural integrity, reduced maintenanceneeds, or other desirable characteristics.

Turning now to FIG. 15, an illustration of a block diagram of a productmanagement system is depicted in accordance with an illustrativeembodiment. Product management system 1500 is a physical hardwaresystem. In this illustrative example, product management system 1500 mayinclude at least one of manufacturing system 1502 or maintenance system1504.

Manufacturing system 1502 is configured to manufacture products, such asaircraft 1400 in FIG. 14. As depicted, manufacturing system 1502includes manufacturing equipment 1506. Manufacturing equipment 1506includes at least one of fabrication equipment 1508 or assemblyequipment 1510.

Fabrication equipment 1508 is equipment that may be used to fabricatecomponents for parts used to form aircraft 1400. For example,fabrication equipment 1508 may include machines and tools. Thesemachines and tools may be at least one of a drill, a hydraulic press, afurnace, a mold, a composite tape laying machine, a vacuum system, alathe, or other suitable types of equipment. Fabrication equipment 1508may be used to fabricate at least one of metal parts, composite parts,semiconductors, circuits, fasteners, ribs, skin panels, spars, antennas,or other suitable types of parts.

In this illustrative example, continuous compression molding fabricationline 102 in FIG. 1 may be included in fabrication equipment 1508. Forexample, continuous compression molding machine 118 may be used tomanufacture thermoplastic composite parts from thermoplastic chargesthat have increased quality as compared to currently manufactured partsusing currently available processes and machines.

Assembly equipment 1510 is equipment used to assemble parts to formaircraft 1400. In particular, assembly equipment 1510 may be used toassemble components and parts to form aircraft 1400. Assembly equipment1510 also may include machines and tools. These machines and tools maybe at least one of a robotic arm, a crawler, a faster installationsystem, a rail-based drilling system, or a robot. Assembly equipment1510 may be used to assemble parts such as seats, horizontalstabilizers, wings, engines, engine housings, landing gear systems, andother parts for aircraft 1400.

In this illustrative example, maintenance system 1504 includesmaintenance equipment 1512. Maintenance equipment 1512 may include anyequipment needed to perform maintenance on aircraft 1400. Maintenanceequipment 1512 may include tools for performing different operations onparts on aircraft 1400. These operations may include at least one ofdisassembling parts, refurbishing parts, inspecting parts, reworkingparts, manufacturing replacement parts, or other operations forperforming maintenance on aircraft 1400. These operations may be forroutine maintenance, inspections, upgrades, refurbishment, or othertypes of maintenance operations.

In the illustrative example, maintenance equipment 1512 may includeultrasonic inspection devices, x-ray imaging systems, vision systems,drills, crawlers, and other suitable device. In some cases, maintenanceequipment 1512 may include fabrication equipment 1508, assemblyequipment 1510, or both to produce and assemble parts that may be neededfor maintenance.

Product management system 1500 also includes control system 1514.Control system 1514 is a hardware system and may also include softwareor other types of components. Control system 1514 is configured tocontrol the operation of at least one of manufacturing system 1502 ormaintenance system 1504. In particular, control system 1514 may controlthe operation of at least one of fabrication equipment 1508, assemblyequipment 1510, or maintenance equipment 1512.

The hardware in control system 1514 may be using hardware that mayinclude computers, circuits, networks, and other types of equipment. Thecontrol may take the form of direct control of manufacturing equipment1506. For example, robots, computer-controlled machines, and otherequipment may be controlled by control system 1514. In otherillustrative examples, control system 1514 may manage operationsperformed by human operators 1516 in manufacturing or performingmaintenance on aircraft 1400. For example, control system 1514 mayassign tasks, provide instructions, display models, or perform otheroperations to manage operations performed by human operators 1516.

In the different illustrative examples, human operators 1516 may operateor interact with at least one of manufacturing equipment 1506,maintenance equipment 1512, or control system 1514. This interaction maybe performed to manufacture aircraft 1400.

Of course, product management system 1500 may be configured to manageother products other than aircraft 1400. Although aircraft managementsystem 1500 has been described with respect to manufacturing in theaerospace industry, product management system 1500 may be configured tomanage products for other industries. For example, product managementsystem 1500 may be configured to manufacture products for the automotiveindustry as well as any other suitable industries. With continuouscompression molding fabrication line 102, product management system 1500may operate with increased efficiencies and lower cost as well asmanufacture thermoplastic composite parts with increased desirablecharacteristics.

In one illustrative example, one or more technical solutions are presentthat overcome a technical problem with manufacturing thermoplasticcomposite parts with a desired level of integrity and consistency. As aresult, one or more technical solutions may provide a technical effectincreasing the level of integrity of thermoplastic composite parts inaddition to increasing other characteristics of the thermoplasticcomposite parts. For example, thermoplastic composite parts manufacturedusing one or more illustrative examples may have at least one ofincreased strength, reduce maintenance, increase longevity, or otherdesirable characteristics.

For example, one or more illustrative examples have a technical effectof reducing residual stresses developed in angles of variable thicknesscomposite parts that occurred during continuous compression machineprocessing. For example, when the flange is positioned at differentangles while the thermoplastic composite part is being formed, theresidual stress buildup at corner radii from holding a flange at agreater angle to take spring back is reduced.

The description of the different illustrative embodiments has beenpresented for purposes of illustration and description and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. The different illustrative examples describe components thatperform actions or operations. In an illustrative embodiment, acomponent may be configured to perform the action or operationdescribed. For example, the component may have a configuration or designfor a structure that provides the component an ability to perform theaction or operation that is described in the illustrative examples asbeing performed by the component.

Many modifications and variations will be apparent to those of ordinaryskill in the art. Further, different illustrative embodiments mayprovide different features as compared to other desirable embodiments.The embodiment or embodiments selected are chosen and described in orderto best explain the principles of the embodiments, the practicalapplication, and to enable others of ordinary skill in the art tounderstand the disclosure for various embodiments with variousmodifications as are suited to the particular use contemplated.

What is claimed is:
 1. A continuous compression molding machine,comprising: a tooling die extending through a heating zone and a coolingzone; a tooling sleeve corresponding to the tooling die, the toolingsleeve to form a thermoplastic composite part from a thermoplasticcomposite charge when the tooling sleeve, together with thethermoplastic composite charge, is moved with respect to the tooling diethrough the heating zone and the cooling zone; and a biasing systemconfigured to hold the thermoplastic composite charge at a first anglewithin at least a portion of the heating zone, and to hold thethermoplastic composite charge at a second angle within at least aportion of the cooling zone, as the tooling sleeve moves through theheating zone and the cooling zone together with the thermoplasticcomposite charge, wherein the first angle is different from the secondangle.
 2. The continuous compression molding machine of claim 1, furthercomprising: a transition section in at least one of the heating zone orthe cooling zone in which a transition from the first angle to thesecond angle occurs.
 3. The continuous compression molding machine ofclaim 1, wherein the biasing system comprises: a guide bar that holdsthe tooling sleeve at the second angle in the cooling zone, such thatthe thermoplastic composite charge is at the second angle.
 4. Thecontinuous compression molding machine of claim 3, wherein the guide barcomprises: an elongate member; and guiding elements that apply pressureto the tooling sleeve such that the tooling sleeve is at the secondangle.
 5. The continuous compression molding machine of claim 3, whereinthe biasing system comprises at least one of a Belleville washer, a coilspring, a leaf spring, a compression spring, a variable spring, a flatspring, a serpentine spring, or a cantilever spring.
 6. The continuouscompression molding machine of claim 1, wherein the tooling die is atthe second angle in the cooling zone.
 7. The continuous compressionmolding machine of claim 1, wherein the biasing system comprises: a sealbar that holds the tooling sleeve at the first angle in the heatingzone.
 8. The continuous compression molding machine of claim 3, whereinthe biasing system comprises at least one of a Belleville washer, a coilspring, a leaf spring, a compression spring, a variable spring, a flatspring, a serpentine spring, or a cantilever spring, that biases a sealbar towards the tooling sleeve.
 9. The continuous compression moldingmachine of claim 7, wherein the biasing system comprises: a key thatbiases the seal bar away from tooling sleeve.
 10. The continuouscompression molding machine of claim 1, wherein the tooling die is anupper tooling die, and the tooling sleeve is a first tooling sleeve; andwherein the continuous compression molding machine further comprises: alower tooling die extending through the heating zone and the coolingzone; and a second tooling sleeve corresponding to the lower toolingdie, the second tooling sleeve to form the thermoplastic composite partfrom the thermoplastic composite charge when the thermoplastic compositecharge is moved with respect to the lower tooling die through theheating zone and the cooling zone; wherein the first tooling sleeve andthe second tooling sleeve are configured to hold portions of thethermoplastic composite charge at a group of first angles within theheating zone and hold the portions of the thermoplastic composite chargeat a group of second angles within the cooling zone as the first toolingsleeve and the second tooling sleeve move through the heating zone andthe cooling zone with the thermoplastic composite charge.
 11. Thecontinuous compression molding machine of claim 1, wherein the toolingsleeve is at the first angle without being biased.
 12. The continuouscompression molding machine of claim 1, wherein the thermoplasticcomposite charge has a flange that is held at the first angle in theheating zone, and at the second angle in the cooling zone.
 13. Thecontinuous compression molding machine of claim 1, wherein the toolingsleeve is comprised of a material that is selected based on atemperature in the heating zone and an ability to return to an originalshape after being held at the second angle.
 14. The continuouscompression molding machine of claim 1, wherein the thermoplasticcomposite part is selected from at least one of a beam, an I-beam, aT-beam, a control surface, a stringer, a stiffener, or a part with ashape having angular features.
 15. A continuous compression moldingmachine comprising: a heating zone; a cooling zone; a tooling dieextending through the heating zone and the cooling zone, the tooling dieincluding a transition section; a tooling sleeve corresponding to thetooling die for forming a thermoplastic composite part from athermoplastic composite charge having a flexible portion when thetooling sleeve together with the thermoplastic composite charge is movedwith respect to the tooling die through the heating zone and the coolingzone; and a biasing system configured to hold the flexible portion ofthe thermoplastic composite charge at a first angle before thetransition section and hold the flexible portion of the thermoplasticcomposite charge at a second angle after the transition section as thetooling sleeve moves through the heating zone and the cooling zonetogether with the thermoplastic composite charge, wherein the firstangle is different from the second angle.
 16. The continuous compressionmolding machine of claim 15, wherein the biasing system comprises atleast one of a guide bar, springs, or a seal bar.
 17. The continuouscompression molding machine of claim 16, wherein the biasing systemprovides a hinge point in the flexible flange of the thermoplasticcomposite charge to enable spring back compensation to reduce residualstresses that develop during processing.
 18. The continuous compressionmolding machine of claim 17, wherein the hinge point is stationary withrespect to the continuous compression molding machine and locatedbetween holding the thermoplastic composite charge at the first angleand holding the thermoplastic composite charge at the second angle. 19.A continuous compression molding machine comprising: a heating zone; acooling zone; a tooling die extending through the heating zone and thecooling zone, the tooling die including a transition section; a toolingsleeve corresponding to the tooling die for forming a thermoplasticcomposite part from a thermoplastic composite charge having a flexibleflange when the tooling sleeve together with the thermoplastic compositecharge is moved with respect to the tooling die through the heating zoneand the cooling zone; and a biasing system configured to hold theflexible flange of the thermoplastic composite charge at a first anglebefore the transition section and hold the flexible flange of thethermoplastic composite charge at a second angle after the transitionsection as the tooling sleeve moves through the heating zone and thecooling zone together with the thermoplastic composite charge, whereinthe first angle is different from the second angle.
 20. The continuouscompression molding machine of claim 19, wherein: the biasing systemcomprises at least one of a guide bar, springs, or a seal bar; thebiasing system provides a hinge point in the flexible flange of thethermoplastic composite charge to enable spring back compensation toreduce residual stresses that develop during processing; and the hingepoint is stationary with respect to the continuous compression moldingmachine and located between holding the thermoplastic composite chargeat the first angle and holding the thermoplastic composite charge at thesecond angle.